[caption id="attachment_66496" align="alignnone" width="595"] The new E&J Gallo North Coast operations offices retained the historic profile of the century-old Olivet Winery. (photo credit: Wright Contracting)[/caption]
Project name: E&J Gallo North Coast offices
Address: 845 Healdsburg Ave., Healdsburg
Owner: E&J Gallo
Project: Renovation of the 109-year-old former Olivet Winery building into a state-of-the-art office building, preserving the red brick double walls and large wood beams.
Cost: $2 million (est.)
Construction: began mid-November 2010, finished mid-February 2012
Design: architecture -- Alan B. Cohen Architect, Healdsburg; landscape -- Green Valley Consulting Engineers, Santa Rosa
Engineering and consulting: civil -- Green Valley Consulting Engineers; electrical -- Suite 16 Electrical Engineering, Santa Rosa; structural - MKM & Associates, Santa Rosa; mechanical -- TEP Engineering, Santa Rosa; geotechnical - PJC & Associates, Cotati; tree relocation -- Becky Duckles Arborist, Sebastopol
Contractors: general -- Wright Contracting, Santa Rosa; plumbing -- Westside Mechanical, Santa Rosa; electrical -- Wiggins Electric, Santa Rosa; roof framing -- Starkey Structures; floor and wall framing -- Petersen Builders, Windsor; paving, grading and bioretention system -- Able General Engineering, Santa Rosa; masonry seismic retrofitting -- Domenichelli Masonry, Healdsburg
Historic-style windows: The Window and Door Shop, San Francisco
HEALDSBURG -- E&J Gallo, one of the world's largest wine companies, wanted to tear down the historic yet inhabitable and graffiti-harried Olivet Winery to construct 15,000 square feet of offices for support employees connected to Gallo's winery in Sonoma County's Dry Creek Valley, yet the Madera-based company ultimately opted for a substantial reconstruction to preserve the bricks and beams of the 109-year-old building.
"It was just assumed it would just be a money pit," said Alan Cohen, the Healdsburg-based architect who convinced Gallo a third site tour to consider reuse of the structure. He then got together with Santa Rosa-based structural engineering firm MKM & Associates to devise a strategy to keep that "pit" about as deep as for a new structure while reinforcing the double-wythe masonry walls to stand up to earthquakes.
The plan called for filling the 8-inch-wide airspace between the brick wythes -- thought to have acted as a thermal chimney to passively cool the building on summer nights -- with steel reinforcing bar and concrete then use a new second floor and roof as a diaphragm to brace the walls. This helped avoid much of the costly buttresses and braces typical of seismic shoring of masonry, according to Mr. Cohen.
"The biggest uncertainty was the structural integrity of the building itself, because it sat vacant for years and had dryrot, the roof and second floor had failed and there was not a foundation, per se, under the walls like today's standards," said Mark Davis, president of project general contractor Wright Contracting.
With new windows built to resemble the originals and taking the structure back to the walls and foundation, the reconstruction would lack the typical uncertainty of rotten wood in framing window cases. But there was the added wrinkle of shoring up the masonry while opening up large portions of the north and south walls to add window curtains, or glass walls, for energy-efficient daylighting of the otherwise dark interior.
The deconstruction and reconstruction was painstakingly methodical.
"It was like taking apart a Tinkertoy set," Mr. Davis said. "Piece by piece, we had to coordinate with MKM and make sure the walls would not collapse."